System and method for mounting photovoltaic panels

ABSTRACT

A system for securing photovoltaic panel modules to a support structure includes a first elongate member securable to the support structure. The first elongate member includes a plurality of first mounting sites positionally fixed thereon. A second elongate member is securable to the support structure. The second elongate member includes a plurality of second mounting sites positionally fixed thereon. The second elongate member is spaced from the first elongate member and aligned therewith in a generally parallel orientation. The position of the first and second elongate members is adjustable to align the first and second fixed mounting sites in a predetermined configuration. When the first and second elongate members are aligned in the predetermined configuration, the plurality of first mounting sites and second mounting sites are brought into alignment with each other to permit mounting of a plurality of panel modules to the first and second elongate members.

The present application claims the benefit of priority to U.S.Provisional Application No. 61/159,677 filed Mar. 12, 2009 and U.S.Provisional Application No. 61/254,974 filed Oct. 26, 2009, and bothapplications are hereby incorporated by reference herein in theirentirety for all purposes.

FIELD OF INVENTION

The present invention relates to a system and method for securing panelsand more particularly to a system and method for photovoltaic panels toa structure.

BACKGROUND OF THE INVENTION

Photovoltaic (“PV”) panels, also known as solar panels, are well knownin the art for converting solar energy into electrical energy. As thedesirability for clean and efficient energy sources increases, so doesthe desire to use power sources such as PV panels.

PV panels are typically mounted on a structure, such as a roof of ahouse or building where they are readily exposed to sunlight. Since thepanels are exposed to the environment, they need to be properly securedto the structure so they can withstand winds and other environmentaleffects. Photovoltaic panels are typically secured to structures by wayof elongated rails secured to the structure. It is known to use variousclamps and hardware which are securable by a threaded bolt and nut to anelongated rail. The clamps may be positioned to engage and secure the PVpanels.

Accordingly, the PV mounting systems of the prior art require thesecurement and adjustment of numerous fastening elements to secure thePV panels. In addition, adjustments as to the position of each panel areoften required which is time consuming and increases the complexity andcost of installation.

When the PV panels are installed, each panel can be wired together andthe wiring is typically terminated in a junction box. In the junctionbox, the PV panel wiring can be connected to the main power line of thesite. PV panels are typically located on the roof of structures,therefore, the panel wiring is often subject to extreme weatheringconditions and abrasion by animals can degrade and damage the wiring'sinsulation. Damage to the wiring requires costly service repairs andkeeps the affected panels offline until such repairs are made. In orderto protect the wiring, it may be run through conventional wire conduit.However, this requires additional components and complicates theinstallation process.

Accordingly, it would be desirable to provide a system and method forsecuring PV panels to a structure in a secure and efficient manner.

SUMMARY

According to aspects described herein, there is disclosed a system forsecuring photovoltaic panel modules to a support structure includes afirst elongate member securable to the support structure. The firstelongate member includes a plurality of first mounting sitespositionally fixed thereon. A second elongate member is securable to thesupport structure. The second elongate member includes a plurality ofsecond mounting sites positionally fixed thereon. The second elongatemember is spaced from the first elongate member and aligned therewith ina generally parallel orientation. The position of the first and secondelongate members is adjustable to align the first and second fixedmounting sites in a predetermined configuration. When the first andsecond elongate members are aligned in the predetermined configuration,the plurality of first mounting sites and second mounting sites arebrought into alignment with each other to permit mounting of a pluralityof panel modules to the first and second elongate members.

According to further aspects described herein, there is disclosed asystem for mounting photovoltaic (PV) panel modules to a supportstructure including a first PV panel module including mountingstructures thereon. A first elongate member is securable to the supportstructure and includes a plurality of first mounting sites positionallyfixed thereon and spaced along a length of the first elongate member. Asecond elongate member is securable to the support structure andincludes a plurality of second mounting sites positionally fixed thereonand spaced along a length of the second elongate member. The secondelongate member is spaced from the first elongate member and alignedtherewith in a generally parallel orientation. The position of the firstand second elongate members is adjustable relative to each other toalign the first and second mounting sites in a configuration to form afirst set of fixed mounting sites corresponding to the mountingstructures on the first PV panel, wherein the first PV panel module issecurable to the first and second elongate members upon cooperation ofthe first set of mounting sites and the mounting structures.

According to still further aspects described herein, there is discloseda method of securing photovoltaic (PV) panel modules to a structureincluding:

adjustably securing a first elongate member having a plurality ofpositionally fixed first mounting sites to the support structure;

securing a second elongate member having a plurality of positionallyfixed second mounting sites to the support structure spaced from thefirst elongate member, wherein the first and second elongate members arein a generally parallel orientation;

adjusting a position of the first elongate member relative to the secondelongate member to place the first and second elongate members in apredetermined alignment, wherein when the first and second elongatemembers are brought into the predetermined alignment, the first andsecond plurality of mounting sites are brought into alignment toaccommodate the mounting of a plurality of PV panel modules;

fixing the position of the first elongate member to maintain thepredetermined alignment;

positioning a first PV panel module having a plurality of positionallyfixed mounting structures over the first and second elongate members;and

securing the first PV panel module to the first and second elongatemembers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the photovoltaic (PV) mounting system secured to astructure in accordance with an embodiment of the present invention;

FIG. 2 depicts a perspective view of the PV mounting system of FIG. 1;

FIG. 3 depicts a perspective view of elongate mounting members and apanel module secured thereto;

FIG. 4 depicts a side perspective view of the PV mounting system of FIG.2 with a panel module positioned for installation on an elongate member;

FIG. 5 depicts a side elevational view of the PV mounting system;

FIG. 6 depicts a side elevational exploded view of the PV mountingsystem;

FIG. 7 depicts a bottom perspective view of the PV mounting system;

FIG. 8 depicts a side perspective exploded view of an alternativeembodiment of a PV mounting system;

FIG. 9 depicts an exploded perspective view of a further alternativeembodiment of a PV mounting system including a partial view of anelongate member;

FIG. 10 depicts a partial cross-sectional side view of the mountingsystem of FIG. 9;

FIG. 11 depicts still a further alternative embodiment of a PV mountingsystem including an end view of an elongate member coupled to a bracket;

FIG. 12 depicts an end view of an elongate member of FIG. 11;

FIG. 13 depicts a perspective view of the elongate member of FIG. 11coupled to a plurality of brackets;

FIG. 14 depicts a perspective view of an attachment device of a PVmounting system;

FIG. 15 depicts an exploded view of the attachment device of FIG. 14;

FIG. 16 depicts a side view of an alternative embodiment of anattachment device;

FIG. 17 depicts an exploded view of the alternative embodiment of theattachment device of FIG. 16;

FIG. 18 depicts a perspective view of a PV panel in a frame;

FIG. 19 depicts an exploded perspective view of a PV panel module ofFIG. 18;

FIG. 20 depicts a cross sectional view of a frame member of the PV panelmodule of FIG. 18; and

FIG. 21 depicts an exemplary PV mounting system after interconnectingthe PV panel modules to the elongate members.

DETAILED DESCRIPTION

Exemplary embodiments are directed to a mounting system for mountingpanels, such as photovoltaic (PV) panels, to a structure, such as a roofon a building. The mounting system allows for one or more, such as anarray, of panels to be mounted in various configurations.

With reference to FIGS. 1-2, the mounting system 10 may be mounted to astructure 12, such as a roof of a commercial or residential building.The mounting system includes panel modules 14 each including PV panel 21for generating electricity. A plurality of panel modules may be mountedside by side forming a row 15. One or more rows of panel modules 14 maybe mounted forming a panel array 17. The array 17 may be electricallyconnected to the electrical service of the building.

Referring to FIGS. 3-4, the mounting system 10 in addition to panelmodules 14 includes brackets 16, elongate members 18, and panelattachment devices 20. The brackets 16 are generally mounted to astructure (e.g., the structure 12), such as the roof of a building andare spaced at a predetermined distance from each other in a row. Thebrackets 16 secure the elongate members 18 to the structure 12 andprovide support to the mounting system 10. The brackets 16 may be in theform of standoffs which space the elongate members from the structure12. A plurality of standoffs 16 may be secured to the support structure12 with mounting hardware 19. A first elongate member 18 a may becoupled to a first row of standoffs 16. A second row of standoffs 16 maybe secured to the support structure 12 to support a second elongatemember 18 b a predetermined distance from the first elongate member asshown in FIG. 3. Multiple pairs of elongate members 18 may be secured tothe support structure 12. It is within the contemplation of the presentinvention that a panel module 14 may be supported by more than twoelongate members 18. The panel modules 14 can be positioned between thespaced elongate members 18 and coupled thereto via attachment devices20.

The standoffs 16 may have a generally L-shaped configuration includingbases 24 having an elongated slot 26 for receiving mounting hardware 19.The slots 26 permit the standoffs and the elongate members 18 attachedthereto to be adjusted closer or further from each other in a directionX generally perpendicular to the length of the elongate members as shownin FIG. 3. The spacing between the standoffs may be set in order toaccommodate the mounting of the panel modules 14.

With reference to FIGS. 3-5, the elongate members 18 are rail-likemembers, with each member having the same or similar configuration. Theelongate members 18 can be formed of metal via an extrusion process,although it is contemplated that other metal forming methods of the typeknown in the art may be used. The elongate members 18 are mounted tostructure 12 via the standoffs 16 in spaced pairings such that theelongate members run generally parallel to each other. An inside face 28of the elongate members 18 may include a T-shaped slot 30 in which thehead of a fastening member 32, such as a bolt, may be inserted and slidtherealong. The fastening members 32 may be attached to the standoffs 16secured to the support structure 12. As shown in FIG. 3, the elongatemembers 18 may be secured end-to-end by a coupling device 33.

When the elongate members 18 are attached to the standoffs 16, thefastening members 32 may be left in a loosened state in order to permitthe elongate members 18 of each pairing to be slid with respect to thestandoffs and each other. The sliding of the elongate members 18 allowsthem each to be positionally adjusted along a Y axis (FIG. 3) withrespect to each other so that the elongate members 18 can be properlyaligned. While both elongate members 18 may be adjustable along the Yaxis, it is also within the contemplation of the present invention thatin an alternative embodiment only one of the elongate members 18 ispositionally adjustable with the other being non-adjustable. The correctpositioning of the elongate members 18 facilitates installation of thepanel modules 14 as described in further detail below. Once thepredetermined proper alignment between the pairing of elongate membersis achieved, the fastening members 32 may be operated on to achieve atightened state, thereby fixing the position of the elongate members 18.When the pair of elongate members 18 are properly aligned and spaced, nofurther adjustments are needed to secure the panel modules 14 in place.

With reference to FIGS. 4, 5 and 6, each of the elongate members 18 canhave a top surface 34 which is generally planar and extends along thelength of the elongate member. The top surface 34 may include aplurality of discrete mounting sites 36 spaced along the length of theelongate member. The mounting sites 36 are positionally fixed to theelongate member 18. The each mounting site 36 may include an attachmentdevice 20 which cooperates with the panel modules 14 for securing thepanel modules 14 to the elongate members 18. The attachment devices 20can be fixedly mounted to the elongate member such that the attachmentdevices are immobile and cannot be moved during installation of theelongate members. In some embodiments, the attachment devices 20 mayinclude upstanding posts 38 fixed to the elongate members 18. The posts38 may include a threaded distal end 37 for receiving a cap nut 39. Thepost 38 may include a bolt 35 a threaded into a sleeve 35 b. The post 38is fixed in position on the elongate member 18. The manner of fixing thepost 38 to the elongate member 18 may include welding, adhesives orother means known in the art.

The panel modules 14 may include a plurality of spaced mounting holes 40formed there-through. The mounting holes 40 may be lined with anelastomeric bushing 41. The posts 38 extend through mounting holes 40formed in the panel modules 14 and the cap nuts 39 are threaded onto theposts to secure the panel modules. The mounting holes 40 can bepositioned inward from the perimeter of the panel modules 14 so thatwhen the panel modules 14 are secured to the elongate members 18, thepanel modules 14 extend beyond the elongate members in the X direction.This allows the panel modules 14 to overhang the elongate members 18 toreduce exposure to the elements of the elongate members 18 and/or wiresand electrical connections.

With further reference to FIGS. 3 and 4, the mounting sites 36 aredisposed on the elongate members 18 at fixed locations. The spacingbetween the mounting sites 36 is such that when the elongate members 18are aligned in a predetermined manner, the mounting sites 36 on oneelongate member 18 cooperate with the mounting sites 36 on the otherelongate member to form a plurality of mounting site sets 42. One set42, for example, includes mounting sites 36 a, 36 b, 36 c and 36 d. Eachmounting site set 42 corresponds to a set of mounting holes 40 in apanel module 14. The sets of mounting sites 42 are spaced so that thepanel modules 14 can be secured to the elongate members 18 in aside-by-side arrangement as shown in FIG. 1. Therefore, when a firstpanel module 14 is installed, the panel mounting holes 40 align with afirst set of mounting sites on the elongate members 18. When a secondpanel module 14 is to be installed next to the first installed panel,the mounting holes 40 in the second panel will align with a second setof mounting sites on the elongate members. Subsequent panel members 18may installed side-by-side on the elongate members 14 forming the panelarray 17 as shown in FIGS. 1 and 2. A set of mounting sites 42 mayinclude 4 mounting sites with two of the mounting points being in eachelongate member. However, it is within the contemplation of the presentinvention that the number of mounting sites may vary.

Accordingly, once the elongate members 18 are properly aligned with eachother, the mounting sites 36 are properly indexed along the length ofthe elongate members so that the panel mounting holes 40 and themounting sites 36 of the elongate members 18 will align, therebypermitting the array of panel modules 14 to be installed and secured.Since the mounting sites 36 are fixed to the elongate members 18, noadjustment of these sites 36 relative to the elongate member 18 isrequired for mounting the panel modules 14 or for removing the panelmodules. In addition, after alignment of the elongate members 18, nofurther adjustment to the positioning of the panels 14 or of theelongate members is required. An installer can easily and efficientlysecure one panel module 14 after the other to the aligned elongatemembers.

The elongate members 18 also facilitate efficient installment of theelectrical wiring running from the panel modules 14. With reference toFIGS. 5-7, the panel modules 14 may include a module junction box 50disposed on the underside of the panel modules 14. The junction box 50provides a termination point for the individual photo cells which makeup the PV panel 21 and allows the electricity generated by the PV panelto be distributed. The junction boxes 50 may include box connectors 52which permit the panel modules 14 to be connected together. The panelmodules 14 may be electrically connected in series and/or parallel inorder to achieve a desired output voltage and/or current. The panelmodules 14 can be then ultimately electrically connected to theelectrical service of the residence or building so that the electricityproduced by the PV panels 21 of the panel modules 14 can be utilized.

The panel modules 14 are secured to the elongate members 18 such thatthe junction boxes 50 are positioned adjacent the same elongate member.In order to electrically interconnect the panel modules 14, at least theelongate member adjacent the junction boxes 50 may include a pluralityof electrical connection stations 54, with a station provided for eachPV panel. Each connection station 54 includes electrical moduleconnectors 56 which connect to the box connectors 52 of the panelmodules 14. The module connectors 56 can be flexible wiring connectorsand/or rigid connectors. The connection between the junction box 50 andthe module connectors 56 can permit the panel modules 14 to be easilyconnected and disconnected, e.g., plugged and unplugged, from the wiringto facilitate ease of installation and/or disassembly.

Wiring 57 from the module connectors 56 can run along the length of theelongate member to a termination point. The wiring on the elongatemembers 18 can be pre-installed. Therefore, an installer would need onlyto connect the junction box 50 to the module connectors 56 to make theelectrical connection for the panel modules 14. In order to provide aprotected path for the wiring 57, a wireway 58 can be included on theelongate member adjacent the junction boxes 50. The wireway 58 mayinclude the connection stations 54 thereon. The wireway 58 may be agenerally C-shaped member and when connected to the elongate member 18forms an enclosed conduit 60. The wireway may be formed of metal,plastic, or other material, such as a carbon composite. The wireway 58may be formed such that it clips onto the elongate member 18. In orderto facilitate this attachment, an outer surface 62 of the elongatemember may include an outwardly extending ridge 64 and an elongatemember bottom surface 66, which may include a downwardly projecting rim68. The wireway may include hook-shaped lip 70 extending along one endwhich engages the rim 68. The other end of the wireway 58 may slip overthe ridge 64, thereby securing the wireway 58 to the elongate member 18.It is within the contemplation of the present invention that the wirewaymay be attached to the elongate members in a number of ways including bythe use of fasteners, such as screws and/or bolts.

In some embodiments, an array of panel modules 14 can be electricallyconnected using a common ground or reference line. The power line can bedivided into segments to connect the positive terminal of a panel moduleto the negative terminal of another panel module. As such, an array ofpanel modules can be electrically connected in a cascading manner wherethe outputs (positive terminals) of a panel module serve as inputs(negative terminal(s)) for the next panel module in the array.

For embodiments in which the panel modules 14 are electrically connectedin a cascading manner an elongate member can be fabricated with thenecessary wiring. For example, a ground or reference line can extend inthe wireway 58 of the elongate member from one end of the elongatemember to the other end as a continuous uninterrupted wire. Each end ofthe reference line can include a termination point having an electricalconnector so that when the elongate members are installed, theelectrical connectors at the terminal points of the reference line canbe connected using the electrical connectors.

Likewise, an elongate member 18 can be fabricated to include the supplyline in the wireway 58 of the elongate member. The supply line can becomposed of separate discontinuous segments of wire. The segments canbegin at one end of the elongate member with a terminal point having anelectrical connector end and can extend to the first one of the moduleconnectors 56 of the elongate member. The next segment can begin fromthe second one of the module connectors 56 and can extend to the nextone of module connectors 56 of the elongate member. The last segment canextend from the last module connector 56 of the elongate member to aterminal point at the other end of the elongate member, which caninclude an electrical connector. In this manner, the supply line of theelongate member can be electrically connected to other elongate membersby connecting the terminal points. By fabricating the elongate memberswith the wiring for electrically connecting the elongate memberstogether via the terminal points, the time and complexity of installingthe elongate member and the panel modules 18 on a structure 12 can bereduced.

Wires 57 interconnecting the various panel modules 14 may be run throughthe conduit 60 created between the wireway 58 and the elongate members18 as shown in FIG. 5. The wireway 58 permits the wires 57 to be neatlyrun in a path and facilitates ease of installation. The wireway 58 alsoprotects the wires 57 from the elements, ultraviolet radiation, androdents. Removal of the wireway allows easy access to the wiring and/orconnectors to facilitate installation and/or maintenance.

With reference to FIG. 8, an alternative embodiment of the elongatemembers is shown. The elongate members 102 may be formed in a mannersimilar to the embodiment described above, except for the wireway beingintegrally formed as part of the elongate member. The elongate members102 may include a top surface 110 having a plurality of fixed mountingsites 112 spaced along the length of the elongate member. Each mountingsite may include an attachment device 114 which cooperates with thepanel module 14 for securing the panel modules 14 to the elongatemembers 102. At least one of the elongate members 102 may include agenerally U-shaped conduit 118 extending along its length. The conduit118 may be integrally formed as part of the elongate members, such as byan extruding process. The conduit 118 may be formed by a wirewayincluding a wall structure 120 extending from the bottom of inside face122 and around a back of the elongate member. The wall structure mayform the outer surface 124 of the elongate member.

The conduit 118 defines a passage through which wiring 125 from thepanel modules 14 may extend. The conduit 118 may be open along the topto permit access to the wiring and module connectors. The opening iscovered when the panel module 14 is installed on the elongate membersdue to the overhang of the panel modules 14. In one embodiment, bothelongate members supporting the panel module 14 may include the conduit.Accordingly, only one type of elongate member would need to be used fora particular installation job. Alternatively, only one of the pair ofelongate members 102, e.g., the elongate members adjacent the junctionbox, may include a conduit.

At predetermined locations along the length of the elongate member,module connectors 125 may be secured to the wall structure and extendoutwardly therefrom.

The module connectors 125 are located so that they will align with thepanel module box connectors 52 to which they are secured.

With reference to FIGS. 9 and 10, a further embodiment is shown. Theelongate members 306 have a generally L-shaped configuration and includean upper portion 312 and a downwardly depending body portion 314 whichall extend along the length of the elongate member 306.

The upper portion 312 preferably includes a planar upper surface thatextends longitudinally along the length of the elongate member 306. Theupper portion 312 of the elongate member 306 preferably has multiplespaced mounting sites 315 in the form of mounting openings 316 formedtherein. The openings 316 can be, for example, holes or slots thatfacilitate coupling of panel modules 14 to the elongate member 306. Theopenings 316 may be spaced at predetermined distances to correspond tomounting holes 317 in the panel modules 14 when the pair of elongatemembers 306 is in alignment with each other. In this manner, theopenings 316 can be indexed to panel module mounting holes 317 so thatthe panel module 14 can be secured to the elongate members 306 viaattachment devices 310.

Body portion 314 extends along the length of an elongate member 306 andis generally configured orthogonally to the upper portion 312. A channel318 is formed in the portion 314 and extends longitudinally along thelength of the body portion 314 to provide an area for receiving mountinghardware 320 to secure the elongate member 306 to standoffs 304. Thechannel 318 allows the elongate members 306 to slide in theirlongitudinal direction before being fixedly positioned. As a result, theelongate members 306 can be aligned with each other so that the openings316 and attachment devices 310 secured therein align with the panelmodule openings 317 to facilitate securing the array of panel modules 14to the elongate members 306. Once the elongate members 306 are properlyaligned, they can be rigidly secured to the standoffs 304 by tighteningfasteners 320. Each pair of elongate members 306 may support one or morepanel modules 14. It is within the contemplation of the presentinvention that a panel module may be supported by more than two elongatemembers.

The panel modules 14 are secured to the elongate members 306 by one ormore attachment devices 310 located at mounting sites 315. Withreference to FIG. 10, the attachment devices 310 preferably include bolt322, a threaded sleeve 324, and a nut 326. In one embodiment, theattachment devices 310 are fixedly attached to the elongate members 306.In the present example, the bolts 322 from multiple attachment devices310 are inserted into the openings 316 of the elongate member 306 suchthat the bolts 322 extend through the openings from the bottom side ofthe upper portion 312. The threaded sleeve can threadingly engage thethreaded rod portion of the bolt on the top side of the upper surface tofixedly secure the bolt 322 to the elongate member 306. The threadedsleeve preferably has a cylindrical configuration; however, thoseskilled in the art will recognize the sleeve can be formed using otherconfigurations, such as a rectangular prism, cube, or hexagonal prism.The panel module mounting holes 317 may be configured based on theconfiguration of the sleeve 324. For example, if the sleeve isconfigured as a rectangular prism the panel module holes 317 can berectangular.

Once the bolts 322 and sleeves 324 are fixed to a pair of elongatemembers 306, the panel module 14 can be aligned so that the panel modulemounting holes 317 align with the openings 316, and therefore, the bolts322 and sleeves 324 also align. The panel module 14 can be moved towardthe upper portion 312 of the elongate member so that the bolt and sleeveextend into the panel module mounting holes 317. After the panel moduleis positioned, the nuts 326 can be used to secure the panel module 14 tothe pair of elongate members 306 by threadingly engaging with an exposedthreaded portion of the bolts 322. In a preferred embodiment, the nut326 is a tamper proof nut that cannot be removed without the use of aspecial tool. In an alternative embodiment, the bolt may be fitted to abushing which is press-fit in to the elongate member openings.

The panel module mounting holes 317 may be lined using a resilientmaterial 329, such as grommets formed from a polymer (e.g. rubber) toprovide a snug but flexible fit for the attachment devices 310, as wellas to protect the panel modules 14 from being damaged by the attachmentdevices 310.

In other embodiments (not shown), the bolt and sleeve can be fixed tothe panel module 14 via panel module openings 317. Subsequently, thepanel module 14 can be aligned so that the openings of the elongatemembers 306 can receive an exposed threaded portion of the bolts 322.The nut 326 then may be secured to the exposed threaded portion of thebolts 322 at the bottom side of the upper surface 312 of the elongatemembers 306 to fixedly secure the panel module 14 to the elongatemembers 1306.

As in the embodiments described above, the elongate members 306 may haveattached to a rear surface thereof a wireway 330. The wireway 330 may besecured to the back side of the elongate member by way of threadedfasteners 332 as shown in FIG. 10. The wireway 330 may be a generallyC-shaped member and when connected to the elongate member 306 forms anenclosed conduit 333. Wires 334 interconnecting the various panelmodules may be run through the conduit 333 created between the wirewayand the elongate members. The wires 334 may be operatively attached toelectrical connectors 336. Electrical connectors 336 connect to junctionbox connectors disposed on the undersurface of the panel modules 14panels in order to provide a way of easily interconnecting the variouspanels to each other.

A further alternative embodiment of the panel mounting system is shownin FIGS. 11-21. The elongate member 500 may include an upper portion502, a connecting portion 506, and a downwardly depending flange 510(hereinafter “flange 510”) which all extend along the length of theelongate member 500. In one embodiment, the elongate member 500generally has a question mark-like cross-sectional configuration.

With reference to FIGS. 11-13, the upper surface 502, extendinglongitudinally along the length of the elongate member 500, may havemultiple mounting sites 503 in the form of mounting openings 504 formedtherein. The openings 504 can be, for example, holes or slots. Theopenings 504 facilitate the coupling of panel modules 507 (FIG. 18) tothe elongate member 500. The openings 504 can be spaced at predetermineddistances so that the panel modules 507 can be secured to the elongatemembers 500 via attachment devices 511 (FIG. 14). The openings can havelongitudinal width that is slightly greater than the width of theattachment devices or may have a longitudinal width that allows theattachment devices to slide in the longitudinal direction. The openings504 can be arranged on the upper surface 502 so that they correspond tothe transverse distance between attachment devices 511 that areconnected to the panel modules 507 (FIG. 18). In this manner, theopenings 504 and the attachment devices 511 for connecting the panelmodules 507 to the elongate members 500 are pre-aligned in thetransverse direction which corresponds to the width of the panelmodules.

With reference to FIG. 12, the connecting portion 506 preferably extendsalong the length of the elongate member 500 and connects the uppersurface 502 to the flange 510. The connecting portion 506 can be acurved, C-like section that forms a longitudinally extending channel508. The channel provides clearance for a portion of the attachmentdevices 511 when they are inserted in the elongate member 500, asdiscussed below. The channel 508 may also provide an area for routing,holding, and protecting wires that connect to the panel modules 507.

The flange 510 extends along the length of an elongate member 500 and isgenerally configured orthogonally to the upper surface 502. A groove 512is formed in the flange 510. The groove 512 extends longitudinally alongthe length of the flange 510 and provides an area to receive mountinghardware 513 (FIG. 11) to secure the elongate member 500 to standoffs514. The orientation of the groove 512 and the channel 508 can besubstantially identical so that the groove 512 and the channel 508 areformed to open in the same direction.

With reference to FIG. 11, the standoff 514 may have a generally rodrod-like configuration. Alternatively, the standoff 514 can beimplemented with other configurations and shapes. The standoff mayinclude a base plate 518 and a shaft portion 520. The base plate 518 andthe shaft portion 520 may be manufactured as a single unitary structure,or may be manufactured as separate components that can be coupledtogether with fastening hardware or other connection devices to form thestandoff 514.

The base plate 518 of the standoff 514 can include openings 522 forreceiving fastening hardware (not shown), such as screws or bolts, forsecuring the standoff to the structure. A distal end of the shaft 520can include a slot 526 formed therein and a threaded opening 528 runningtransverse to the direction of the slot 526. The slot 526 is configuredto receive elongate member flange 510. The elongate member 500 can besecured in the slot 526 using mounting hardware 530, such as a setscrew.

To connect the standoff 514 and the elongate member 500, the flange 510of the elongate member 500 is disposed in standoff slot 526. The depthof the slot 526 may be such that when the flange 510 sits on the bottomof the slot 526, the groove 512 generally aligns with the opening 528.The elongate members 500 may be slide with respect to the standoffs sothat the members may be properly aligned to mount the panel modules.Once the proper alignment is achieved, the elongate members 500 may thenbe secured to a standoff 514 by the insertion of mounting hardware 530,which extends through the opening 528 at the distal end of the standoff514 and engages the groove 512. Since the end of the mounting hardware530 engages the groove 512 of the flange 510, removal of the elongatemember 500 in the longitudinal direction of the standoff 514 isprevented. Therefore, forces, such as those caused by wind, tending toseparate the elongate members, and panel module secured thereto, fromthe support structure are resisted.

With the elongate members 500 secured, the panel modules 507 may beselectively locked to the elongate members 500 by one or more attachmentdevices 511. The attachment devices permit attachment of the panelmodules to the elongate members 500 without tools. With reference toFIGS. 14 and 15, each attachment device 511 may include a housing member710, a resilient locking member 730, a resilient ring 750, a bolt 770, awasher 780, and a nut 790. The housing member 710 may be configured in agenerally cylindrical manner. The housing member 710 may have a sidewall712, a top surface 714 and a bottom surface 715 that is similar to thetop surface 714. The sidewall 712 extends radially about a longitudinalaxis of the housing member 710 and has an opening 716 formed therein forreceiving a portion of the resilient locking member 730. The top surface714 and bottom surface 715 may include openings 718 for receiving bolt770 therethrough.

The resilient locking member 730 has a generally curved or C-shapedconfiguration having a curved portion 732 extending radially about alongitudinal axis of the resilient locking member 730. The resilientlocking member 730 is configured to be inserted into the housing member710. The curved portion 732 may generally resist being compressed in aradially inward manner and may be composed of a steel spring. Theresilient locking member 730 can include a raised portion 734 disposedon the curved portion 732, which forms a locking member of theattachment assembly 511 for selectively locking the panel modules 507 tothe elongate members 500. The raised portion 734 can be configured toengage and extend through the opening 716 of the housing member 710 sothat the raised portion 734 protrudes from the housing member 710 whenthe resilient locking member 730 is inserted into the housing member710. The resilient locking member 730 tends to urge the raised portion734 in an outwardly extending position through the opening 716 of thehousing member 710. The raised portion 734 can have a ramp-like end 736such that a bottom portion 738 of the raised portion 734 extends awayfrom the curved portion 732 to a distance that is less than the distancethat a top portion 740 extends away from the curved portion 732.

The resilient ring 750 is an annular member having an opening 752 therethrough which the bolt 770 may extend into. The resilient ring 750 canbe formed of a resilient material that can be slightly compressed underthe exertion of a compressive force, but that generally resists suchcompression. The resilient ring 750 may be aligned adjacent to thehousing member 710 so that the opening 718 of the housing member 710substantially aligns with the opening 752 of the resilient ring 750.

The bolt 770 can extend through the openings 718 in the top surface 714and the bottom surface 715 of the housing member 710, the opening 752 ofresilient ring 750, and an opening in the washer 780. A distal end 772of the bolt 770 can engage the nut 790 to secure the housing member 710,the resilient ring, and the washer 780 of the attachment assembly 511 tothe panel module 507.

Referring to FIGS. 16 and 17, another embodiment of an attachmentassembly 800 is provided. The attachment device 800 can include ahousing member 810, a rod 830, and a resilient locking member 850. Thehousing member 810 preferably has a generally parabolic or conicalconfiguration and is preferably formed from a co-molded plastic. Thehousing member 810 can have a first end 812 and a second end 814. Thesecond end 814 can include a surface 818 for closing the housing member810. The surface 818 preferably includes an opening 820 for receivingthe rod 830. The housing member 810 preferably includes one or moreopenings 816, which may be formed towards the second end 814 of thehousing member 810.

The rod 830 preferably has a distal end 834 and a proximate end 836. Athreaded section 838 is preferably formed at the distal end 834 forthreadingly engaging a bolt or the panel module. The proximate end 836can be coupled to the resilient member 850 using a fastening mechanism,such as a press fit connection formed by a rivet, a weld, or a screw.

The resilient locking member 850 is preferably formed from a resilientmaterial, such as a steel spring, so that absent any external forces,the resilient locking member 850 tends to return to its natural state.The resilient locking member has a longitudinally extending body 852with a first end 854 and a second end 856. As discussed above, theresilient member 850 can be coupled to the threaded rod 830. When theattachment device, is assembled the resilient locking member 850 and theproximate end 836 of the rod 830 can be inserted into the housing member810 towards the first end 812. During insertion, the resilient member850 can bend inwardly towards the rod 830. The resilient locking member850 generally resists bending inwardly, but is held in place by thehousing member. The first and second ends 854 and 856 of the resilientlocking member 850 can extend through the openings 816 of the housingmember so that the first and second ends 854 and 856 protrude from thehousing member 810. Alternatively, the resilient locking member 850 canbe preformed to fit within the housing member in its natural state sothat the housing member does not force, or applies only a small force,to the resilient locking member 850.

Elongate members may have openings formed therein to accept the housingmember 810. In order to attach the panels to the elongate members, theconical housings are pushed into the openings until the locking memberends 854 and 856 go through. The end will then spring out therebyretaining the attachment device and the panel secured thereto to theelongate members. A resilient ring 870 may be disposed between the panelframe and the elongate member in order to keep tension on the lockingmember ends 854 and 856 and create a tight attachment.

In the embodiments described above, the mounting holes are formed in thePV panel itself, therefore, no panel frame is needed. However, it isalso within the contemplation of the present invention, that the panelmodule may include a frame which holds the PV panel. The frame may thenbe attached to the elongate members. As shown in FIGS. 18 to 20, thepanel module 507 may includes frame members 910, support members 930,and a PV panel 950. The frame members surround the perimeter of the PVpanel 950 and retain the edges of the panel. Frame members 910 may havea lip 912, a notched section 914, a slotted section 916, and a bottomsection 918. The lip 912 and the notched section 914 provide a region onthe frame members 910 for supporting the PV panel 950. The PV panel 950can be inserted into the notched section 914 and can be pressed againstthe lip 912. Once in place, the PV panel 950 can be secured using thesupport members 930, as discussed below. The slotted section 916 can beformed in the frame members 910 to provide an area for a portion of theattachment device 511 to extend into. The bottom section 918 can beadjacent to the slotted section 916 and can have a generally planarbottom surface 920. The bottom section 918 can have an opening 922 forreceiving and being secured to the attachment device 511.

The frame member 910 may further include a longitudinally extendingchannel formed by the slotted section 916. The openings 922 can beformed in the bottom section 918 transverse to the channel formed fromthe slotted section 916. The channel receives the end of the bolt andallows access to a fastening element such as a nut. In a preferredembodiment, four attachment devices 511 are attached to each PV panel950, although more or less attachment devices 511 could be used. Thedistance between the elongate members 500 secured to a support structureis preferably set such that the distance between the mounting openings504 of one elongate member to an opposing elongate member equals thedistance between the mounting devices 511 on the panel modules 507 inorder to facilitate attachment of the panel modules 507 to the elongatemembers 500.

The support members 930 can be attached to the frame members 910 usingany mechanism for attaching, such as adhesive, screws, nails, nuts andbolts, etc. The support members 930 can be attached to the notchedsection 914 of the frame members 910 so that a portion of the PV panel950, such as a perimeter of the PV panel is sandwiched between the lip912 of the frame member 910 and the support member 930.

The panel members are made of a natural substance such as wood.Laminated bamboo has been found to provide desirable benefits. It is,however, within the contemplation of the present invention that theframe may be made of a plastic or a metallic material. With regard to ametallic frame such as aluminum, since a metallic frame conductselectricity, it is required under various building codes that the framebe grounded. The connection of grounding wiring to each panel is timeconsuming and expensive. Accordingly, the use of an insulating materialsuch as wood eliminates the need to include such electrical groundingstructure. Furthermore, the use of laminated bamboo can be made in anenvironmentally conscious manner eliminating negative environmentalimpacts associated with the production of the system.

FIG. 21 depicts an exemplary connection of the panel module 507 and theattachment device 511. The attachment device 511 can be secured to theframe member 910 of the panel module 507 using the bolt 770 and nut 790of the attachment device 511. Multiple attachment devices 511 can besecured to the panel module 507. In an exemplary embodiment, fourattachment devices 511 can be secured to each panel module 507.

To secure the panel module 507 to the elongate members 500, theattachment devices 511 are secured to the panel module 507. The elongatemembers 500 are aligned and secured to the standoffs 514 to prevent anyfurther movement. The attachment devices 511 are placed in line with theopenings 504 in the upper surface 502 of the elongate members 500. Theelongate members having been previously aligned, the position of theopenings 504 correspond to the position of the attachment devices 511.The housing members 710 of the attachment devices 511 are insertedthrough the openings 504. While the housing members 710 are beinginserted, the raised portion 734 of the resilient members deflectradially inwardly so that the housing members 710 fit through theopenings 504. Once the housing members 710 and raised portions 734 arepassed the thickness of the upper surface 502 of the elongate members500, the raised portions 734 re-extends radially outwardly toselectively lock the attachment device 511 in the elongate member 500.The panel module 507 is thereby secured to the elongate members 500. Asecond panel module may be secured to the elongate members 500 adjacentto the first panel module in a similar manner. Since the elongatemembers are aligned all the openings 504 along the length of theelongate members are properly aligned to receive the attachment devices511 of the panel modules. If removal of a panel module 507 is desired,an installer simply needs to reach underneath the panel module 507 andengage the raised portions 734 pressing them inwardly to unlock thepanel modules 507 and to lift on the panel module 507. Therefore, thepanel modules 507 may then be selectively locked to the elongate members500 without requiring the use of tools.

As shown in FIG. 21, the resilient ring 750 may be compressed betweenthe upper surface 502 of the elongate member 500 and the bottom section918 of the frame member 910 to allow the housing member and the raisedportion 734 to pass the thickness of the upper surface 502 of theelongate member 500. The resilient ring can remain slightly compressedbetween the bottom section 918 of the frame member 910 and the uppersurface 502 of the elongate member 500. Once the housing member isinserted, the raised portion 734 extends beyond a radial distance of theopening 504 and effectively secures the panel module 507 to the elongatemember 500. The resilient ring 750 can remain slightly compressed sothat the attachment device 511 securely locks the panel module 507 tothe elongate member 500. The resilient ring 750 also accommodates forthermal expansion of the various components and various manufacturingtolerances.

In an alternative embodiment (not shown), the attachment devices 511 maybe secured to the elongate member 500 at the mounting sites 503 and thepanel modules may include openings for receiving the attachmentassemblies. In addition, the attachment devices 511 and 800, may be usewith frameless panel modules and secured to mounting openings formed inthe PV panel.

Having described the preferred embodiments herein, it should now beappreciated that variations may be made thereto without departing fromthe contemplated scope of the invention. Accordingly, the preferredembodiments described herein are deemed illustrative rather thanlimiting the true scope of the invention being set forth in the claimsappended hereto.

1-26. (canceled)
 27. A photovoltaic (PV) panel module mountable to amounting structure comprising: a frameless PV panel defined by an outerperimeter, the PV panel including a plurality of spaced mounting holesformed there-through, the mounting holes being disposed inwardly fromthe PV panel perimeter, the mounting holes being adapted to receivemounting hardware for securing the PV panel to the mounting structure.28. The PV panel module of claim 27, wherein the mounting holes arelined with a bushing.
 29. The PV panel module of claim 28, wherein thebushing is formed of an elastomeric material.
 30. The PV panel module ofclaim 27, wherein the PV panel includes a junction box disposed thereon,the junction box providing a termination point for individual photocells which make up the PV panel.
 31. The PV panel module of claim 27,wherein the junction box is disposed on an undersurface of the PV panel.32. The PV panel module of claim 27, wherein the PV panel includes aplurality of solar cells and the mounting holes are disposed on the PVpanel between the plurality of solar cells.